Underdeck ceiling and collector system

ABSTRACT

A ceiling system includes ceiling members that are supported intermediate their ends, are positioned to catch liquid and debris from above, and provide a pleasing appearance from below, while still being easily removed individually from the ceiling. The ceiling system may be installed under a deck support structure and provide adjacent ceiling members having nested male and female inverted J-shaped legs extending upwardly. The nested legs of the ceiling members are suspended on downwardly extending J-shaped hooks mounted to the support structure in an array. The hooks are positioned to define a clearance space between hooks such that the female leg of an adjacent ceiling member can be raised into a clearance space to allow removal of a nested male leg of a ceiling member being removed from the ceiling. The system can be configured so that the ceiling members are supported without being held in place by fasteners, and removal of the ceiling members occurs without the removal of any such fasteners.

BACKGROUND OF THE INVENTION

1. Technical Field

The present invention relates to removable ceiling installations, andmore particularly to an underdeck ceiling and water collection system.

2. Description of Related Art

Attempts have been made to provide undercover systems for decks toprevent water and debris passing through the deck floorboards fromreaching the space beneath the deck. Some such systems are permanentlyinstalled below the deck, creating difficulties when it is necessary toclear away debris that has fallen between deck floorboards into thecollection system. Other systems do not provide a level of finishedappearance desired for more expensive homes. U.S. Pat. No. 6,226,941 toStevens purports to describe an undercover system in which watercollection panels are not permanently attached to the building structureand which can be cleaned. However, the collection panels span an entiredimension of the deck without intermediate support, and as a resulttheir weight is borne by substantial tubular beams underlying the endsof the panels. This requires relatively complex and expensivemanufacture of components for the system. Other underdeck systems aredescribed in U.S. Pat. Nos. 6,279,271 and 7,434,358.

BRIEF SUMMARY OF THE INVENTION

The present invention seeks to provide solutions to problems in thefield by providing a ceiling system including ceiling members that aresupported intermediate their ends while still being easily removedindividually from the ceiling, are positioned to catch liquid and debrisfrom above, and provide a pleasing appearance from below. The system canbe configured so that the ceiling members are supported without beingheld in place by fasteners, and removal of the ceiling members can occurwithout the removal of any such fasteners.

The present invention accomplishes these objectives by providing,according to one of its embodiments, a ceiling system for installationunder a support structure comprising a plurality of ceiling members,each such ceiling member including an elongate panel, at least oneinverted J-shaped female leg opening in a first direction and extendingupwardly from the panel and outwardly beyond a first elongate side edgeof the elongate panel, and at least one inverted J-shaped male legopening in the first direction and extending upwardly, the male legbeing positioned at or proximate a second elongate side edge of theelongate panel and shaped to nest within a female leg of an adjacentceiling member; and a plurality of downwardly extending J-shaped hooksmounted to the support structure in an array, each of the plurality ofhooks opening in a second direction and shaped to receive one of themale legs and one of the female legs, wherein two of the ceiling membersare positioned adjacent to one another with the male leg of one of theceiling members nested within the female leg of the adjacent ceilingmember and the nested legs supported on at least one of the hooks, andthe hooks are positioned to define a clearance space therebetween suchthat the female leg of the adjacent ceiling member is liftable into theclearance space and the male leg of the one ceiling member is removablefrom its supporting hook.

According to an embodiment of the invention, the hooks may be defined ina track, wherein at least a first hook and a second hook of theplurality of hooks are spaced apart by a distance selected to positionthe first hook to receive the male leg of the one ceiling member and toposition the second hook to receive the female leg of the one ceilingmember. The track may be a strip of sheet material defining a cutouttherein defining the J-shaped hooks; and a plurality of fasteneropenings defined in an area of the strip extending above the cutout. Themale and female legs may each comprise a continuous leg along arespective one of the elongate side edges of the elongate panel.

The system may further comprise a plurality of downwardly extendingJ-shaped finishing hooks mounted to the support structure and opening inthe first direction and shaped to receive at least one leg of a finishceiling member. The finish ceiling member may comprise an elongatefinish panel, at least one of the inverted J-shaped male legs opening inthe first direction along a first elongate finish panel side edge, andat least one inverted L-shaped finish leg extending upwardly andinwardly from a second elongate finish panel side edge, and wherein atleast two of the plurality of finish hooks are spaced apart along thesecond elongate finish panel side edge. The inverted L-shaped finish legof the finish ceiling member may comprise a continuous finish legdefining a plurality of cutouts spaced to allow passage of thespaced-apart finish hooks therethrough.

According to an embodiment of the invention, the system includes anelongate gutter member, wherein the gutter member is mounted transverseto a lower end of each of the plurality of adjacent ceiling members anddefines a trough positioned to receive water from the lower ended of theadjacent ceiling members. The gutter member may further comprise anattachment flange positioned to be attached to the support structure.

According to an embodiment of the invention, the tracks may be bentbetween the cutout and the plurality of fastener openings such that thestrip can be mounted to the support structure via the fastener openings.Further, the strip may be bendable at two places to allow selection ofthe distance between the support structure and the hooks.

According to a further embodiment, the invention provides an integralblank of sheet material comprising a strip of sheet material; aplurality of spaced-apart cutouts in the strip defining a plurality ofJ-shaped hooks; and a plurality of fastener openings defined in an areaof the strip extending above the cutouts. Each cutout may extend from anopen side of one of the J-shaped hooks to a closed side of an adjacentJ-shaped hook and define a supporting buttress integral with the closedside of the J-shaped hook. The strip may include at least one line ofweakness between a pair of the hooks at which the strip may beseparated. The strip may be bent longitudinally between the cutouts andthe plurality of fastener openings to provide a fastener flange.Further, the strip may be bendable at two places to allow selection ofthe distance between the fastener flange and the hooks.

BRIEF DESCRIPTION OF THE DRAWINGS

Having thus described the invention in general terms, reference will nowbe made to the accompanying drawings, which are not necessarily drawn toscale, and wherein:

FIG. 1 is a perspective view of an underdeck collector system, frombelow, according to an embodiment of the invention.

FIG. 2 is another perspective view of the underdeck collector system,from above with deck flooring absent, according to an embodiment of theinvention.

FIG. 3 is a bottom-up view of the underdeck collector system, prior toinstallation of ceiling members, according to an embodiment of theinvention.

FIG. 4 is a cross-sectional view of a ceiling member, according to anembodiment of the invention.

FIG. 5 is a cross-sectional view of a finish ceiling member, accordingto an embodiment of the invention.

FIG. 6 is a perspective view of a finish ceiling member, according to anembodiment of the invention.

FIG. 7 is a plan view of a hanger track, according to an embodiment ofthe invention.

FIG. 8 is a plan view of a finish hook unit, according to an embodimentof the invention.

FIG. 9 is a plan view of a hanger track along with a cross-sectionalview of a plurality of installed adjacent ceiling members, according toan embodiment of the invention, taken along line 9-9.

FIG. 10 is a plan view of a hanger track and a finish hook unit alongwith cross-sectional view of an installed finish ceiling member and anadjacent ceiling member, according to an embodiment of the invention,taken along line 10-10.

FIG. 11A is a cross-sectional view of the higher end of the underdeckcollector system, according to an embodiment of the invention, takenalong line 11A-11A.

FIG. 11B is a cross-sectional view of the gutter end of the underdeckcollector system, according to an embodiment of the invention, takenalong line 11B-11B.

FIG. 12 is another perspective view of the underdeck collector system,showing installed ceiling members, according to an embodiment of theinvention.

FIG. 13 is a pictorial view of a section of a main track after bendingto form a fastener flange.

DETAILED DESCRIPTION OF THE INVENTION

The present invention now will be described more fully hereinafter withreference to the accompanying drawings, in which some, but not allembodiments of the inventions are shown. Indeed, these inventions may beembodied in many different forms and should not be construed as limitedto the embodiments set forth herein; rather, these embodiments areprovided so that this disclosure will satisfy applicable legalrequirements. Like numbers refer to like elements throughout.

When describing parts of the present invention, words of orientation,such as “above” and “below” are sometimes used to indicate relativeposition, rather than an orientation with respect to the earth'sgravitational field. Reference should be had to the context to determinewhether a relative or gravitational orientation is intended.

Overview

The present disclosure, according to various embodiments, provides foran underdeck collector system that is designed to be installed under adeck support structure to collect fluids, in including rain water, thatpass through the deck, and to drain the fluids towards a gutter in orderto prevent the fluids from falling onto the area under the deck. Theunderdeck collector system includes a plurality of adjacent ceilingmembers that form a ceiling under the deck. The ceiling members are hungon an array of hooks that are mounted to the support structure in such amanner to allow the ceiling members to form a ceiling when installed.Additionally, the hooks are designed to enable individual ceilingmembers to be removed from the underdeck collector system without havingto remove all of the ceiling members. Furthermore, the ceiling membersfunction as a drainage system for the fluids that pass through the deck,as fluids are collected on the top of each ceiling member and drainedtowards the gutter. To facilitate the drainage towards the gutter, thehooks are situated so that one end of the ceiling members is moreelevated than the other end of the ceiling members, thus allowing thefluids to flow downward toward the gutter, which is situated proximatethe lower ends of the ceiling members. Fluids are able to collect in thegutter and may be further drained from the gutter though one or moredownspouts (not shown) that may be positioned to receive the fluids fromthe gutter.

DESCRIPTION

Reference is now made to FIGS. 1-3, which represents the generalassembly of the underdeck collector system 10, according to anembodiment of the present invention. The underdeck collector systemresides below the deck support structure 17, the support structureitself being supported by one or more support posts 18. The supportstructure typically is provided by a plurality of spaced apartconventional ceiling joists 19. The underdeck collector system 10includes a plurality of ceiling members 11 and a finish ceiling member12 that are supported below the support structure 17 by a plurality ofdownwardly extending hooks and a plurality of finish hooks mounted tothe support structure in an array. In particular embodiments, acontinuous track defines at least two of the plurality of hooks, and oneor more tracks are mounted to the support structure to support theceiling members 11 and finish ceiling member 12, in a manner describedin more detail below. In other embodiments, two tracks are employed tosupport the ceiling members, the tracks including a higher trackassembly 13 and a lower track assembly 14. The higher track supports ahigher end of the ceiling members 11 and finish ceiling member 12 at ahigher elevation than the lower track 14 supports a lower end of theceiling members 11 and finish ceiling member 12 at a lower elevation toenable fluids to drain from the higher end of the ceiling to the lowerend of the ceiling.

Furthermore, according to embodiments of the present invention, theunderdeck collector system 10 includes an elongate higher end cap 15 andan elongate gutter member 16. The higher end cap 15 is mounted to thesupport structure 17, is situated transverse to the length of theceiling members 11 and finish ceiling member 12, and is positioned toreceive the higher ends of the ceiling members 11 and 12. The guttermember 16 is mounted to the support structure 17 at the opposite (lower)ends of the ceiling members 11 and finish ceiling member 12, situatedtransverse to and positioned to receive their lower ends. The higherends of the ceiling members 11 and finish ceiling member 12 rest on thehigher end cap 15 and the lower end of the ceiling members 11 and finishceiling member 12 rest on the gutter member 16 in a manner described inmore detail below. The gutter member 16 defines a trough positioned toreceive fluids from the lower end of the ceiling members 11 and finishceiling member 12, also described in more detail below.

FIG. 3 depicts a view of the underdeck collector system 10 from below,according to an embodiment of the invention, with the ceiling members 11and finish ceiling member 12 uninstalled to expose the hangingstructure. The higher track 13 and lower track 14 assemblies eachinclude a main track 30 a, 30 b, respectively, and a finish hook unit 31a, 31 b, respectively, at one end of the main track 30 a or 30 b. Eachmain track 30 a, 30 b is designed to support the ceiling members 11 andeach finish hook unit 31 a, 31 b is designed to support the finishceiling member 12 in a manner described below.

Furthermore, according to embodiments of the present invention, theunderdeck collector system 10 includes an elongate higher end cap 15 andan elongate gutter member 16. The higher end cap 15 is mounted to thesupport structure 17 and situated proximate the higher track 13 in aposition where the higher end of the ceiling members 11 and finishceiling member 12 may rest transverse to the higher end cap 15 when theceiling members 11 and finish ceiling member 12 are installed. Thegutter member 16 is mounted to the support structure 17 and situatedproximate the lower track 14 in a position where the lower end of theceiling members 11 and finish ceiling member 12 may rest transverse thegutter member 16 when the ceiling members 11 and finish ceiling member12 are installed.

FIG. 4 is a cross-sectional view of a ceiling member 11, according to anembodiment of the invention. The ceiling member 11 includes an elongatepanel 110. The bottom side of the elongate panel 110 serves as theceiling on the underside of the underdeck collector system 10 and thetop side of the elongate panel 110 serves to receive fluid that passesthrough the support structure 17. The ceiling member 11 also includes atleast one J-shaped female leg 111 extending upwardly from the elongatepanel 110 and outwardly beyond a first elongate side edge of theelongate panel 110 and opening in a first direction. Additionally, theceiling member 11 includes at least one inverted J-shaped male leg 112extending upwardly from a second elongate side edge of the elongatepanel 110 and also opening in the first direction. The male and femalelegs are shaped so that the male leg 112 can nest within a female leg111 of an adjacent ceiling member 11 as best shown in FIG. 9. In variousembodiments of the present invention, the male leg 112 and the femaleleg 112 are each a continuous leg along a respective one of the elongatesides of the elongate panel 110, in which case the panel 110 and legs111 and 112 are formed by bending the material of the ceiling memberfrom a flat sheet. The male leg 112 may optionally be positionedproximate to, but spaced inwardly from, the second elongate edge of thepanel 110.

FIGS. 5 and 6 show the finish ceiling member 12, according to anembodiment of the invention. The finish ceiling member 12 includes anelongate finish panel 120, in which a bottom side of the elongate finishpanel 120 serves as the ceiling on the underside of the underdeckcollector system 10 and in which a top side of the elongate finish panel120 serves to receive fluid that passes through the support structure17. At least one J-shaped male leg 121 extends upwardly from a firstelongate side edge of the finish panel 120 and opens in the firstdirection (the same direction upon installation in which the J-shapedmale leg 112 of a ceiling member 11 opens). Additionally, the ceilingmember includes at least one inverted L-shaped finish leg 122 extendingupwardly and inwardly from a second elongate finish panel 120 side edge,opening in a second direction opposite the first direction. As willbecome clear, the finish ceiling member 120 is used only as the last ina series of ceiling members following one or more ceiling members 11.The finish ceiling member is supported in part by one or more finishhook units 31 a, 31 b. The width of the finish ceiling member 12typically is varied to adjust for the dimension of the deck structure,so that the ceiling members 11 can have a standard width matching thefixed distance between hooks of the tracks to be described below.

As shown in FIG. 6, the inverted L-shaped finish leg 122 defines one ormore finish leg cutouts 123 in the inwardly extending portion of the leg122. The cutouts 123 are positioned to allow passage of spaced-apartfinish hooks 311 there through during installation, as will be describedin connection with FIG. 10.

FIG. 7 depicts a plan view of a track 30 from which a segment 30 a ofthe higher track assembly 13 and also a segment 30 b of the lower trackassembly 14 depicted above in FIG. 3 can be made, according to anembodiment of the present invention. The track 30 defines at least twoof a plurality of hooks 302 that are designed to support the ceilingmembers 11 and finish ceiling member 12. When installed, the hooks 302open in the second direction opposite to the first direction in whichthe J-shaped legs 111 and 112 open.

In particular embodiments, the track 30 is an integral blank 306 ofsheet material, for example a strip of sheet metal, in which a pluralityof spaced-apart cutouts 304 define the plurality of hooks 302 and inwhich a plurality of fastener openings 307 are defined in an area of thestrip extending above the cutouts 304. Two parallel rows 316 and 317 offastener openings 307 may be provided. Each of the plurality of hooks302 is shaped to receive one of the male legs 112 and one of the femalelegs 111 of a ceiling member 11, and each of the plurality of hooks 302opens in the same direction as the other hooks 302. In variousembodiments, the plurality of hooks 302 define J-shaped hooks, and ineven further embodiments, the plurality of hooks 302 define downwardlyextending J-shaped hooks. Other shapes and orientations for the hooks302 may be employed, according to embodiments of the present invention.Within the integral blank, each cutout 304 extends from an open side ofone of the J-shaped hooks 302 to a closed side of an adjacent, orsecond, J-shaped hook 302. Furthermore, each cutout is shaped such thateach J-shaped hook 302 includes a supporting buttress 305 integral withthe closed side of the J-shaped hook 302.

In addition, the integral blank 306 is bendable longitudinally above thecutouts 304, for example at a right angle to form a fastener flange 320,as shown in FIG. 13. The bend may be positioned to place either only row316 of openings in the flange, or both rows 316 and 317 in the flange.The openings 307 in the flange may then be used to mount the track tothe underside of the support structure 17 with the hooks 302 extendingdownwardly there from. To form a track 30 a with a hook structure thatextends a shorter distance from the support structure, suitable for thehigher track assembly 13, the integral blank is bendable along a creaseline 309 located such that both rows 316 and 317 of fastener openingsreside on a flange 320 a. In the alternative, the integral blank isbendable along a crease line 308 located between the rows of openings316 and 317, so that only the openings 316 are in a flange 320 b of atrack 30 b as shown in FIG. 13. This creates a longer hook structuresuitable for the lower track assembly 14, which is mounted closer to thegutter 16. In this way the slope needed for the ceiling members whenhung on the track assemblies can be provided using one base manufacturedpart 30 that can be fabricated by bending in two different places.

Furthermore, the integral blank 306 may include at least one line ofweakness 301 between a pair of the downwardly extending J-shaped hooks302, formed by a line of perforations through the sheet material. Thelines of weakness allow the integral blank to be broken apart into oneor more hook units 300, according to an embodiment of the presentinvention. However, the lines of weakness do not significantlycompromise the structural integrity of the track assembly, because thefastener flange 320 can be attached to the support structure betweenevery pair of lines of weakness. Each hook unit 300 includes at leastone of the cutouts 304 and at least one of the J-shaped hooks 302, and aplurality of fastener openings 307 defined in the area of the fastenerflange 320 associated with the unit 300.

FIG. 8 is a plan view of a finish hook unit 31, according to anembodiment of the present invention. The finish hook unit 31 includes afinish strip of material 315, from which a finish hook 311 is cut out atone end, and a plurality of fastener openings 312 defined in an area ofthe finish hook unit 31 above the finish hook 311. In one embodiment, asshown, one row of slots 322 is spaced inwardly from an elongate edge ofthe unit 31 opposite the hook 311, and an array of circular holes 323are formed between the row of slots and the hook. The finish hook 311 isshaped to receive the finish leg 122 of a finish ceiling member 12. Invarious embodiments, the finish hook 311 defines a J-shaped hook, and infurther embodiments, the finish hook 31 defines a downwardly extendingJ-shaped hook. In particular embodiments, the finish hook 311 opens inthe first direction, opposite to the second direction in which thedownwardly extending J-shaped hooks 302 open. Other shapes andorientations for the finish hook 311 may be employed, according toembodiments of the present invention.

In addition, the finish hook unit 31 is bendable like the track 30 atdifferent crease lines with respect to the fastener openings 322 and 323to form a fastener flange 325, such that when the finish hook unit 31 isbent it can be mounted to the underside of the support structure 17. Tofabricate a finish hook unit compatible with the higher track assembly13, the finish hook unit 31 is bendable along a crease line 314 locatedto create a fastener flange 325 a and to position the finish hook 311 atthe same distance below the support structure as the hooks 302 of thehigher track assembly 13. In the alternative, the finish hook unit 31 isbendable along a crease line 313 located between a top row of fasteneropenings 322 and of the circular fastener openings 323. This creates afinish hook unit with a fastener flange 325 b in which the hooks 311will extend below the support structure the same distance as the hooks302 of the lower track assembly 14.

FIG. 9 is a plan view of a hanger track 30 a along with across-sectional view of a plurality of installed adjacent ceilingmembers 11 a, 11 b, 11 c, according to an embodiment of the invention.The track 30 a includes at least two hooks 302 on which a plurality ofceiling members 11 are supported. The plurality of hooks 302 are mountedto the support structure 17 in an array, and each of the plurality ofhooks 302 open in a second direction in comparison to the direction inwhich the J-shaped female leg 111 and the J-shaped male leg 112 of eachof the ceiling members 11 open. In addition, two of the ceiling members11 are positioned adjacent to one another with the male leg 112 of oneof the ceiling members 11 a nested within the female leg 111 of theadjacent ceiling member 11 b, and such nested legs 111, 112 aresupported on at least one of the hooks 302. In particular, at least afirst hook 302 a and a second hook 302 b of the plurality of hooks arespaced apart by a distance selected to position the first hook 302 a toreceive the male leg 112 of one ceiling member 11 a and to position thesecond hook 302 b to receive the female leg 111 of the same ceilingmember 11 a. This design is continued throughout the length of the track30 a. In the embodiment shown, the adjacent ceiling members areconstructed so that their respective nested legs abut approximately atthe respective panels 120 to form a visually pleasing seam in theceiling.

With reference to FIG. 3, it can be seen that the configuration of FIG.9 is found in both the higher and lower track assemblies 13 and 14, withthe exception that the hooks 302 extend down further from the supportstructure in the lower track assembly 14 and the fastener flange 320 isnarrower. The two track assemblies are sufficient to support the weightof several lengthy ceiling members 11, 12 when the track material is,for example, about 0.07 inch thick galvanized steel sheet, and theceiling members are made, for example, from about 0.03 inch galvanizedsteel sheet. Furthermore, the hooks 302 are shaped and positioned todefine a clearance space there between such that the female leg 112 ofone ceiling member 11 a can be lifted into an adjacent cutout 304allowing the male leg 112 of the adjacent ceiling member 11 b to beremoved from its supporting hook 302 a to permit full removal of theceiling member without removing other ceiling members, as described indetail below.

Although the hooks 302 are shown provided along a one-piece track, thehooks can be provided on individual members attached to the supportstructure in a spaced array suitable for hanging the ceiling members.

FIG. 10 is a plan view of a hanger track 30 a and a finish hook unit 31a along with cross-sectional view of an installed finish ceiling member12 and an adjacent ceiling member 11, according to an embodiment of theinvention. The track 30 a and the finish hook unit 31 a combine to formboth the higher track assembly 13, as depicted in FIG. 3. It will beunderstood that the track 30 b and finish hook unit 31 b are similar,except for narrower fastener flanges 320 b and 325 b. The track 30 aincludes a hook 302 at the end of the track 30 a, opening in the seconddirection. The finish hook unit 31 a includes a finish hook 311 openingin the first direction that is substantially opposite the directiontoward which each of the plurality of hooks 302 opens. The finish hook311 is shaped to receive the inverted L-shaped finish leg 122 of thefinish ceiling member 12, while the adjacent hook 302 is spaced from thefinish hook 311 and positioned to receive the male leg 121 of the finishceiling member 12, as well as the female leg 111 of an adjacent ceilingmember 11. The finish hook unit 31 a can be secured to the supportstructure in this position, and further can be secured to theoverlapping track 30 a by drilling holes in the track at one or more ofthe openings 323, and inserting fasteners such as sheet metal screws ornuts and bolts (not shown).

FIGS. 11A and 11B depict the relation of the ceiling members 11 and/orfinish ceiling member 12 to the higher end cap 15 and the gutter member16, according to an embodiment of the invention. As shown in FIGS. 1, 3and 11A, the higher end cap 15 encloses the upper ends of the ceilingmembers 11, 12. According to one embodiment, the higher end cap isformed from an integral sheet bent to include a vertical panel 153, areinforced flange 151 extending approximately horizontally from a bottomedge of the vertical panel, and a flashing panel 152 extending outwardlywhile sloping downwardly from an upper edge of the vertical panel 153.The flange 151 is folded back on itself to form a double thickness toreinforce the strength of the flange, although it does not bear theweight of the ceiling members. The flashing panel 152 can be secured tothe support structure near the vertical panel. Its slope helps to directwater from above into the ceiling members 11, 12.

The higher end cap 15 is mounted to the support structure parallel tothe tracks 30 adjacent to the extending ends of the ceiling members 11,12 so that the extending ends of the ceiling panels are positioned, wheninstallation is complete, spaced apart from the vertical panel 153 butcovered from below by the flange panel 151.

FIG. 11B is a cross-sectional view of the gutter end of the underdeckcollector system, according to an embodiment of the invention. Accordingto one embodiment, the gutter end member 16 is formed from an integralsheet bent to define a gutter trough 160 from a vertical back panel 162,a bottom panel 161, a vertical front panel 163, and a lip 164 extendingfrom a top edge of the vertical front panel toward the back panel 162. Agutter attachment flange 165 extends from a top edge of the verticalback panel horizontally over the bottom panel to allow the gutter 16 tobe secured to the support structure 17. When the ceiling members areinstalled, lower ends of the ceiling members 11, 12 extend beyond thelip 164, and terminate spaced apart from the vertical back panel 162.Thus, the trough 160 is positioned to receive fluids such as rain waterfrom the lower end of the ceiling members 11, 12. The vertical backpanel 162 may be made in a trapezoidal shape (not shown) to provide aslope along the gutter for water discharge from one of its ends. In thealternative, the gutter 16 may be installed at an angle (for exampledefined by shims) to provide a slope.

According to an embodiment of the invention, the overall length of eachof the ceiling panels 11, 12 is shorter than the distance between theinstalled positions of the vertical panel 153 of the higher end cap 15and the vertical back panel 162 of the gutter 16, for example, by about2 inches. This end gap tolerance allows the ceiling members to bemanipulated during installation and removal as described below, and todrain into the trough 160. In many installations, the ceiling members11, 12 will be of approximately equal length and the end members 15 and16 will be approximately parallel to one another. However, when supportstructure is not rectangular, the end members may follow its curvatureor corners, and the ceiling members may be varied in length so that asimilar end gap tolerance is maintained.

Assembly

The underdeck collector system 10 according to embodiments of thepresent invention typically is installed after construction of a deckhaving a support structure 17 including a plurality of spaced apart,parallel floor joists. Building walls often lie closely adjacent to oneor more edges of the deck structure. The purpose of the underdeckcollector system 10 is to provide a ceiling under the floor joists 19that can prevent rain water, other liquids, dirt, and debris fromfalling through the deck flooring and joists onto the area below thedeck, and also can provide a pleasing appearance. Given a deckstructure, ceiling members 11, a finish ceiling member 12, typically twotrack units 30 a, 30 b bent to provide higher and lower hooks, a higherend cap 15, and a gutter end piece 16, are manufactured to fit the spaceusing conventional sheet metal fabrication equipment. Track pieces canbe trimmed to length using the lines of weakness 301.

Installation according to an embodiment of the inventions begins bysecuring the track assemblies 13 and 14 to the underside of the joists19 of the support structure 17, positioning the track assembliesparallel to one another and spaced inwardly from the respective edges ofthe deck that run transverse to the joists, as shown in FIG. 3. This isdone by driving fasteners, such as nails or screws (not shown), throughthe flanges 320 into the joists. Main track sections 30 a, 30 b extendfrom a first outside joist to a position providing a hook 302 atapproximately the width of the finish ceiling member 12 from theopposite extreme joist (typically the innermost joist). Then, as shownin FIGS. 3 and 10, finish hook units 31 a, 31 b are installed to spanthe space to be occupied by the finish ceiling member 12.

Before or after installation of the track assemblies, the higher end cap15 and the gutter 16 are installed by driving similar fasteners upthrough the flashing 152 and the gutter attachment flange 165,respectively, into the joists near respective ends of the joists.Typically, the higher end cap 15 will be positioned adjacent to andalong a building wall, with the flashing 152 and reinforced flange 151extending under the joists toward the tracks. The gutter 16 will bepositioned along the opposite edge of the deck away from the buildingwall, with the trough 160 opening under the joists and toward thetracks. If another building wall or the like restricts space along thedeck at one of the ends of the track assemblies, then that end isselected to receive the finish hook units 31. If the deck is bounded bywalls on three sides, both ends of the track assemblies may be providedwith finish hook units 31. If desired, a downspout (not shown) may beconnected to carry water from the gutter 16.

The installation shown in FIGS. 1-3 is an example in which there issufficient clearance at the end of the track assemblies opposite thefinish hook units 31 to hang a male leg 112 over the outermost hooks302. The ceiling members 11, 12 can be installed or removed in anysequence, but initial installation proceeds most efficiently if thefinish ceiling member 12 is installed first, so that female legs 111 arehung over previously positioned male legs as additional ceiling membersare installed.

Turning to the finish ceiling member 12, the male leg 121 is hung on thehooks 302 of the tracks 30 closest to the finish hook units 31.Generally described, the cutouts 123 in the inverted L-shaped leg 122are passed over the hooks 311, requiring little clearance between thehook 311 and an adjacent wall. Then the ceiling member 12 is slid into aposition in which a solid portion of the leg 122 rests on each hook 311,and the ends of the ceiling member are positioned one over thereinforced flange 151 and the other over the trough 160. Described inmore detail, it will be seen that one of the cutouts 123 is spaced fromone end of the ceiling member a distance to allow that (lower) end toclear the gutter 16 as the ceiling member is raised past the hooks 311of the unit 31 b. Then that lower end of the ceiling member can be slidfarther than its final distance into the gutter. At that position, thesecond cutout 123 is positioned at the other hook 311 of the unit 31 a,and the other (upper) end of the ceiling member can clear the flange 151as the cutout is raised past the hook 311. Then the ceiling member isslid back toward the vertical panel 153 until the upper end reaches itsfinal position above the flange 151, with the lower end emptying intothe gutter and both ends hidden from below.

One of the ceiling members 11 then is installed under the tracksadjacent to the finish ceiling member by hanging its female leg 111 onthe same hooks 302 of the track assemblies 13 and 14 that previouslyreceived the male leg 121 of the finish ceiling member 12, and hangingits male leg 112 over the next hooks 302, as best shown in FIG. 9. As inthe case of the finish ceiling member, the ceiling member 11 is jockeyedfirst to position a lower end farther than its final distance into thegutter in order to raise the other end past the flange 151; then theceiling member is moved to its final position with the legs over thehooks 302 as described. This process is repeated until all the ceilingmembers 11 are hung in place. FIG. 12 shows some of the ceiling membersinstalled.

The ceiling members' weight is borne by the tracks 30, 31, not by theflange 151 or gutter 16, although the ceiling member may or may nottouch the flange 151 or lip 164. Furthermore, the cutouts 304 do notreduce the weight bearing strength of the tracks, because the verticalspan of track material adjacent each hook 302 is intact.

The configuration of the tracks 30 and ceiling members 11 allow easyremoval and installation of any individual ceiling member withoutremoval of adjacent ceiling members, taking advantage of the cutouts 304provided for this purpose. Each ceiling member 11 a when installed has amale leg 112 trapped by a female leg 111 of a first adjacent ceilingmember 11 b, and a female leg 111 resting on a male leg 112 of a secondadjacent ceiling member 11 e, as shown in FIG. 9. To remove the ceilingmember 11 a, one raises the female leg of the member 11 b into thedotted line position shown in FIG. 9, that is, up into the cutout 304.This allows the male leg 112 to be removed from the hook 302 a as thefemale leg 111 is removed from the hook 302 b. To reinstall the ceilingmember 11 a, again the female leg of member 11 b is raised to allowpositioning of the male leg 112 of member 11 a onto the hook 302 a.

It should be noted that during installation and use of the system, inthe disclosed embodiment no fasteners of any type need secure theceiling members to any track, to any joist or other part of the supportstructure, or to any other ceiling member. Likewise, removal ofindividual ceiling members can occur without removal of any fasteners.Fasteners could be added as desired, but they are not required.

Many modifications and other embodiments of the inventions set forthherein will come to mind to one skilled in the art to which theseinventions pertain having the benefit of the teachings presented in theforegoing descriptions and the associated drawings. Therefore, it is tobe understood that the inventions are not to be limited to the specificembodiments disclosed and that modifications and other embodiments areintended to be included within the scope of the appended claims.Although specific terms are employed herein, they are used in a genericand descriptive sense only and not for purposes of limitation.

1. A ceiling system for installation under a support structurecomprising: a plurality of ceiling members, each said ceiling memberincluding: an elongate panel, at least one inverted J-shaped female legopening in a first direction and extending upwardly from said panel andoutwardly beyond a first elongate side edge of the elongate panel, andat least one inverted J-shaped male leg opening in the first directionand extending upwardly, said male leg being positioned at or proximate asecond elongate side edge of the elongate panel and shaped to nestwithin a female leg of an adjacent ceiling member; and a plurality ofdownwardly extending J-shaped hooks mounted to the support structure inan array, each of said plurality of hooks opening in a second directionand shaped to receive one of said male legs and one of said female legs,wherein: two of said ceiling members are positioned adjacent to oneanother with the male leg of one of the ceiling members nested withinthe female leg of the adjacent ceiling member and said nested legssupported on at least one of the hooks, and said hooks are positioned todefine a clearance space therebetween such that the female leg of theadjacent ceiling member is liftable into the clearance space and themale leg of the one ceiling member is removable from its supportinghook.
 2. The ceiling system of claim 1, wherein a track defines at leasttwo of the plurality of hooks, wherein at least a first hook and asecond hook of the plurality of hooks are spaced apart by a distanceselected to position the first hook to receive the male leg of the oneceiling member and to position the second hook to receive the female legof the one ceiling member.
 3. The ceiling system of claim 1 furthercomprising a plurality of downwardly extending J-shaped finishing hooksmounted to the support structure and opening in the first direction andshaped to receive at least one of said legs of a finish ceiling member.4. The system of claim 3 wherein said finish ceiling member comprises:an elongate finish panel, at least one of said inverted J-shaped malelegs opening in the first direction along a first elongate finish panelside edge, and at least one inverted L-shaped finish leg extendingupwardly and inwardly from a second elongate finish panel side edge, andwherein: at least two of the plurality of finish hooks are spaced apartalong the second elongate finish panel side edge.
 5. The system of claim4, wherein the at least one inverted L-shaped finish leg of the finishceiling member comprises a continuous finish leg defining a plurality ofcutouts spaced to allow passage of the spaced-apart finish hookstherethrough.
 6. The system of claim 1, wherein the male and female legseach comprise a continuous leg along a respective one of the elongateside edges of the elongate panel.
 7. The system of claim 1 furthercomprising an elongate gutter member, wherein said gutter member ismounted transverse to a lower end of each of the plurality of adjacentceiling members and defines a trough positioned to receive water fromthe lower ended of the adjacent ceiling members.
 8. The system of claim1, said gutter member further comprising an attachment flange positionedto be attached to the support structure.
 9. The system of claim 1,wherein each of the plurality of hooks comprises: a strip of sheetmaterial; a cutout in the strip of sheet material defining one of saidJ-shaped hooks; and a plurality of fastener openings defined in an areaof the strip extending above the cutout.
 10. The system of claim 9,wherein each of the plurality of hooks is bent between the cutout andthe plurality of fastener openings such that the strip can be mounted tothe support structure via said fastener openings.
 11. The system ofclaim 10, wherein the plurality of fastener openings comprises two rowsof fastener openings.
 12. The system of claim 11, wherein at least oneof the plurality of hooks is bent such that both rows of fasteneropenings reside on a fastener flange, said fastener flange being mountedto the support structure proximate a higher end of each of the pluralityof adjacent ceiling members.
 13. The system of claim 11, wherein atleast one of the plurality of hooks is bent between a top row offastener openings and a bottom row of fastener openings, said at leastone of the plurality of hooks being mounted to the support structure bythe top row of fastener openings and proximate a lower end of each ofthe plurality of ceiling members.
 14. The system of claim 1, whereinduring use of the system, no fasteners secure said ceiling members tosaid hooks.
 15. An integral blank of sheet material comprising: a stripof sheet material; a plurality of spaced-apart cutouts in the stripdefining a plurality of J-shaped hooks; and a plurality of fasteneropenings defined in an area of the strip extending above the cutouts.16. The integral blank of claim 15, wherein each cutout extends from anopen side of one of the J-shaped hooks to a closed side of an adjacentJ-shaped hook.
 17. The integral blank of claim 15, wherein each cutoutis shaped such that each J-shaped hook includes a supporting buttressintegral with the closed side of the J-shaped hook.
 18. The integralblank of claim 15, wherein said integral blank is bent between at leastsome of the plurality of cutouts and the plurality of fastener openings.19. The integral blank of claim 18, wherein the plurality of fasteneropenings comprises two rows of fastener openings.
 20. The integral blankof claim 19, wherein said integral blank is bent such that both rows offastener openings reside on a shared surface of the integral blank whenbent.
 21. The integral blank of claim 19, wherein said integral blank isbent between the two rows of fastener openings.
 22. The integral blankof claim 15, wherein said integral blank includes at least one line ofweakness between a pair of said hooks at which the integral blank mayseparated.
 23. The integral blank of claim 22, wherein each at least oneline of weakness divides the integral blank into a plurality of hookunits, each of said plurality of hook units including: at least one ofthe plurality of cutouts in the strip defining a J-shaped hook; and aplurality of fastener openings defined in an area of the strip extendingabove said at least one of the plurality of cutouts.